Universal system for the support and positioning of a workpiece
This is a continuation of U.S. patent application Ser. No. 07/440,594, filed Nov. 22, 1989 now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
     This invention relates qenerally to workpiece holders and, more particularly, to a method and apparatus for supporting and positioning of a workpiece for use in an inspection system incorporating an inspection probe. 
     2. Discussion 
     To use an inspection system to measure a workpiece it is highly beneficial and, for the most part, a requirement that the workpiece being inspected is positioned in a high precision inspection configuration and maintained in that position. 
     The conventional workpiece holder for an inspection system generally uses a single type of positioning device at a variety of locations on the workpiece. Moreover, the positioning devices are usually specially made for a specific workpiece and cannot be used for other workpieces. In other words, conventional workpiece positioning and holding devices lacked universality in that a single set of positioning devices could not be used for virtually any shape or size of workpiece. 
     U.S. Pat. No. 4,641,819 to Poland discloses a jig assembly for holding a variety of workpieces for assembly or machining processes. Individual workpiece positioners are permanently attached to a base portion in a matrix configuration. Each positioner can be raised or lowered, and can reach points within a certain range by rotating a tip around three axes A, B and C. It appears that the workpiece rests on a supporting ledge adjacent the tip. This patent suffers the drawbacks of not being truly universal. Further, one axis cannot be adjusted without affecting the other two. 
     U.S. Pat. No. 3,681,834 to Seidenfaden discloses a fixing and tensioning system for workpieces to be mechanically processed. A template is used over a platform having a uniform rectangular grid. The template indicates the positions for modular units for supporting different workpieces. The modular units are not adjustable on three axes to provide true universality of the system. 
     British Patent No. 764,351 discloses a jig assembly for supporting motor vehicle body shells of differing sizes. A series of location units are arranged on a platform having a number of places for securing the units. The units can be moved to other locations on the platform to support other sized vehicle frames. The location units do not appear to be adjustable. 
     Another workpiece support and positioning device manufactured by the Milford Fabricating Company, a division of the assignee of this invention, is known in the art. This device comprises a plurality of individual support elements positionable at different locations on a platform. 
     This invention eliminates the above-described problems as well as many others. Up until now a truly universal workpiece positioning and supporting system was not known. This invention enables ease of change from one workpiece to another using the same set of holding and positioning devices. 
     SUMMARY OF THE INVENTION 
     An apparatus made in accordance with the teachings of the present invention includes a set of adjustable alignment devices positioned in a predetermined arrangement on a platform. The platform includes a matrix of threaded holes in which the alignment devices are removably inserted. By inserting the alignment devices in different holes and then providing three-dimensional positional adjustments of a contact head on each device, a number of widely varying workpieces can be positioned using the same set of alignment devices. 
     In the preferred embodiment, each alignment device is built from a plurality of reusable and interchangeable elements which are interconnected together to provide unique functions. These functions include support, clamping, datum locating and providing reference points. Many of the alignment devices have at least one element in common, preferably posts or stanchions. Stanchions come in varying lengths and can be connected together. Most of the alignment devices are adjustable in three independent axes, in which one axis can be adjusted without affecting the other two. The versatility of the alignment devices provides a support and positioning system which is truly universal. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These and other advantages of the present invention will become apparent to those skilled in the art after studying the following text and by reference to the drawings in which: 
     FIG. 1 is a perspective view which illustrates a set of alignment devices supporting and positioning a specific workpiece; 
     FIG. 2 is an exploded perspective view which illustrates one of the alignment devices used for support; 
     FIG. 3 is an exploded perspective view which illustrates one of the alignment devices for use as a reference point; 
     FIG. 4 is a exploded perspective view which illustrates one of the alignment devices for use as a clamp; 
     FIG. 5 is an exploded perspective view which illustrates an alignment device which is used as an A datum locator; 
     FIG. 6 is an exploded perspective view which illustrates one of the alignment devices which is an A and C datum locator; 
     FIG. 7 is an exploded perspective view which illustrates one of the alignment devices which is a B or C datum locator; and 
     FIG. 8 is an exploded perspective view which illustrates one of the alignment devices which is a flush mounted B or C datum locator. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 shows the preferred embodiment of the workpiece supporting apparatus 10 of the present invention. In this embodiment a workpiece 14, in this case a hood for an automobile, is shown being supported and positioned by a plurality of alignment devices. The alignment devices are threaded into holes 16 of a platform 12. The threaded holes 16 in the platform 12 are arranged in a predetermined matrix having an adequate distance from each other such that the alignment devices can position virtually any size and shape workpiece. In the preferred embodiment, holes 16 are arranged in a rectangular array spaced 100 mm apart. As can be seen from FIG. 1, the workpiece 14 is positioned in a body position, i.e., the position it would be in in normal use. 
     As can be readily noticed from FIG. 1, the alignment devices provide different types of functions. Alignment devices 18 provide reference points (described below) for an inspection probe used with computerized inspection equipment such as a digimatic indicator (not shown). Alignment devices 20 provide support for the workpiece at specific datum points. Alignment devices 22 provide a clamping function by holding down the top of the workpiece. A second alignment device is generally used as a support at a specific datum point beneath the clamping alignment devices 22. In FIG. 1, alignment devices 24 and 26 act as an A datum locator and an A and C datum locator, respectively, with clamping alignment devices 22. Alignment devices 28 are used as B or C datum locators. These alignment devices keep the workpiece 14 at a specific transverse location. In FIG. 1, alignment devices 30 pushes the workpiece against a B or C datum locator (e.g. 26 or 28). 
     The positioning of the alignment devices in the platform 12 of FIG. 1 is for the specific workpiece 14 shown. It can be readily apparent that each alignment device can be easily removed from the threaded hole in which it is in and put into another hole. As will become apparent, most of the individual alignment devices have a contaot portion contacting the workpiece which can be adjusted in all three X, Y and Z axes after they are positioned in one or more of the holes. Each alignment device has a sufficient range of movement of the contact portion that it is possible to place it at any location along the platform 16. Therefore, the alignment devices are truly universal and can virtually support and position any workpiece for inspection. 
     Now turning to FIG. 2, support alignment device 20 is shown in more detail. As can be seen, stanchion 32 is threaded into a hole 16 of platform 12 at the desired support location. Threaded tip portion 86 of stanchion 32 is inserted into hole 16 and finger tightened. Rod 40 is then inserted into hole 88 of stanchion 32 to further tighten it into hole 16. Stanchion 32 has an upper end with an internal threaded bore 38. Either another stanchion 32 can be inserted into this threaded bore 38 by means of tip portion 86, or end cap 106 can be threaded into the bore 38. Stanchions 32 are provided in varying lengths. Therefore, many different heights can be accessed by a contact portion or tip 136. Also, the end of tip 136 can be manufactured into a variety of different shapes, such as a tip having a flat surface, an angled surface, a rounded surface, etc. End cap 106 also has an internal threaded bore 34. Into that bore is threaded support tip 136. Once the exact height of alignment device 20 is determined, nut 134 secures the tip 136 at this location. Device 20 is thus typically used for support of the workpiece, usually at a specific control point. 
     FIG. 3 shows the referencing alignment device 18. The stanchion 32 is used to bring a referencing point to nearly the height desired. The upper end of stanchion 32 is inserted into hole 44 at one end of a horizontal clamping member 42. Bolts 48 are then inserted as shown, and tightened to clamp the clamping member 42 to the stanchion 32. At the other end of the horizontal clamping member 42 is another hole 46. A projection from a horizontal rotating member 56 is inserted into hole 46. Horizontal rotating member 56 can be rotated 360° in a plane parallel to the plane of the horizontal clamping member 42. The projection has two flanges 52 which define groove 54. Once the projection is in hole 46, set screws 50 are inserted through the horizontal clamping member 42 into groove 54, as shown, to secure the horizontal rotating member 56 into place. The horizontal rotating member 56 has a horizontally extending hole 102 through it. An extension rod 58 is inserted into hole 102 and secured by set screws 50 as shown. Extension rod 58 can be rotated about its axis 360°  before being secured in a specific location by set screws 50. The extension rod 58 is threaded on its inside and has an outward threaded tip at one end. The end having the threaded tip is threaded into a vertical support element 60 as shown. The vertical support element 60 has a tab 80 on one side. The tab 80 is inserted between projections 82 of a vertical positioning member 68. A rod 76 is inserted through the projections 82 of the vertical positioning member 68 and through the tab 80 to secure the twb together A locking key 78 locks the vertical positioning member 68 in a vertical position. At the other end of the vertical positioning member 68 are two other projections 84. A tab 70 from a horizontal positioning member 72 is inserted between projections 84 to secure the horizontal positioning member 72 to the vertical positioning member 68. Set screws as shown secure the two together in a specific angular configuration relative to a plane of the workpiece. Both the vertical positioning member 68 and the horizontal positioning member 72 have slots 66 and 74, respectively. Both of these slots hold separate reference bushings 64. The reference bushings are secured to the slot using nuts 62, as shown. 
     In operation, the reference alignment device 18 is adjusted by the above mentioned elements to bring the reference bushings 62 to predetermined positions relative to workpiece 14. The alignment device 18 does not touch the workpiece. A probe from an inspecton system (not shown) is inserted into the two reference bushings 64 in order to determine referencing dimensions for measuring the dimensions of the workpiece 14. Once the reference dimension is determined by the probe and recorded, the locking key 78 can be removed and the positioning members 68 and 72 holding the reference bushings 64 can be moved away from workpiece 14. 
     Turning to FIG. 4, an alignment device 22 generally used as a clamp is shown. The compbnents or elements of this device are the same as the alignment device 18 of FIG. 3 from the support stanchion 32 to the extension rod 58 Inserted onto the horizontal extension rod 58 of the alignment device 22 is a horizontal support plate 90. Horizontal support plate 90 has a number of holes 92 in which a commercially available locking device 100 is secured in place by bolts 94, as shown. 
     In operation, the clamping alignment device 22 is positioned in a hole 16 at the point which clamping is desired. A tip 98 of clamping device 22 should be clamped at an appropriate point on the workpiece to avoid any skewing forces on the workpiece, i.e., at a point where the tip is perpendicular to a plane of the workpiece. To do this, extension rod 58 and horizontal rotaing member 56 are rotated to appropriate positions. Before positioning the alignment device 22, lever 96 of the locking device 100 is pulled back such that tip 98 is loose. Once the desired position is attained, lever 96 is then pushed into an upright position forcing tip 98 down into the position as shown in FIG. 4 locking the tip 98 into a clamping arrangement against the workpiece. Clamping device 22 isgenerally used with an A datum locator, as shown in FIG. 1. Similarly, the clamping device 100 can be replaced by a clamping device (also commercially available) shown generally at 30 of FIG. 1. This clamping device is generally used with a B or C datum locator, as shown in FIG. 1. 
     Turning now to FIG. 5, A datum locator alignment device 24, generally used underneath clamping alignment device 22 of FIG. 4 is shown. As can be seen, this alignment device generally uses two stanchions. The stanchions 32 have end caps 106 threaded into their upper ends as in FIG. 2. A bridging member 112 is secured to both end caps 106. The end caps 106 are inserted into recesses 148 until flange 146 is flush with the bottom of bridging memeber 112. Set screws 115 are secured within groove 110 formed by flanges 108. The bridging member 112 has a horizontal dovetail retaining slot 114 all the way across it. This slot 114 enables a sliding assembly 126 to be positioned anywhere alonq slot 114. The sliding assembly 126 has a projection 118 extending downwardly from it. This projection has a sliding plate 120 secured to it by means of bolt 122. The projection 118 also has flanges 124 forming a groove 140. Sliding assembly 126 also has a horizontal dovetail retaining slot 142. This retaining slot is for sliding assembly I28. Sliding assembly 128 has the same type of projection 118 as sliding assembly 126. Sliding assembly 128 has a threaded hole in its upper face in which a vertical supporting tip 136 is inserted. Vertioal supportinq tip 136 is threaded into hole 138 to the desired distanoe and looked there by nut 134. A rest cap 132 is then positioned at the end of the vertical supporting tip 136. 
     In operation, the A datum alignment device 24 is positioned in two threaded holes 16 at nearly the desired location. The proximate Z position is determined by the length and number of stanchions 32. Once this position is set, fine tuning of the X, Y and Z direction can be accomplished by the above-described elements. Once the horizontal direction (e.g. X direction) along slot 114 of bridging member 112 is determined, sliding assembly 126 is locked in place by two methods. First, bolt 122 secures sliding plate 120 to sliding assembly 126 in a loose fashion before being inserted into the dovetail horizontal retaining slot 114. Once the sliding assembly 126 is in the desired location in slot 114, bolt 122 is tightened, drawing sliding plate 120 up flush against flange 144 represented by the dovetail slot 114. The bottom portion of sliding assembly 126 is then tightened against the top of the bridging member 112. Set screws 116 are then tightened into grcove 140 to further secure assembly 126 in slot 114. Sliding assembly 128 is secured in dovetail retaining slot 142 of sliding assembly 126 in the same manner, to move tip 136in a horizontal direction (e.g. Y direction) perpendicular to the horizontal direction (e.g. X direction) of the slot 114 in bridging member 112. Bolt 130 retains assembly 128 into sliding assembly 126. Vertical positioning tip 136 provided the fine tuning in the Z direction. Since the A datum alignment device 24 is often used with the clamping alignment device 18, there may be substantial pressure put against tip 136 and may provide damage to the workpiece 14. Rest cap 132 provides a wider base in which to clamp against. Further, extension rod 58 can be used to extend the vertical distance of tip 136. The threaded end portion of rod 58 can be threaded into hole 138. Tip 136 is then threaded into the threaded hole at the opposite end of rod 58. 
     By the arrangement shown in FIG. 5 it can be realized that virtually any point within the range of the alignment device can be supported by tip 136. The range of the alignment device is sufficiently large that every point in the X-Y platform plane can be accessed by tip 136 by the appropriate selection of mounting holes 16 and fine tuning adjustment provided by the unique construction of the adjustable elements of the alignment devices. Also, when adjusting one axis, the other two axes are not disturbed. Thus, high precision adjustment of one axis can be performed. 
     Now turning to FIG. 6, A andC datum locator alignment device 26 is shown. Alignment device 26 provides both an A datum supporting function (via tip 136) and a C datum positioning function (via tip 154), as can be seen by FIG. 1. The elements of alignment device 26 are similar to those of alignment device 24 from stanchion 32 to sliding assembly 126. Instead of sliding assembly 128 as in FIG. 5, alignment device 26 has an L-shaped sliding assembly 162, secured in the horizontal dovetail slot 142 as discussed before. Sliding assembly 162 has a vertical retaining slot 152 which secures a vertical sliding member 150 in a variable Z direction. This is accomplished by inserting a tab portion 160 of vertical sliding member 150 into slot 152 as shown. The vertical sliding member 150 is retained in the retaining slot 152 by means of a vertical sliding plate 164 and a bolt 158 as shown. The vertical (A datum) supporting tip 136 is similar to that shown in FIG. 5. A horizontal (C datum) positioning tip 154 is secured into vertical sliding member 150 by a threaded hole and is adjustible therein. The tip 154 is then locked in a desired location by nut 156. 
     In operation, vertical tip 136 can be used with a clamping alignment device 22 and at the same time tip 154 can be used with an alignment device 30 that pushes against an edge of the workpiece 14 as can be seen in FIG. 1. Once again, extension rod 58 can be used to extend tips 136 and 154 as described above. Also, tips with different end configurations, as described above, can be used. 
     Turning now to FIG. 7, B or C datum locator alignment device 28 is shown. The elements from stanchion 32 to the sliding assembly 126 are the same as in FIGS. 5 and 6. Sliding assembly 128 or 162 is now replaced with sliding assembly 166. The sliding assembly 166 is secured into the dovetail slot 142 of sliding assembly 126 by means of bolts 168 in the same fashion as described above. Sliding assembly 166 contains a vertical retaining slot 170 for vertically positioning a sliding assembly 172. Sliding assembly 172 is secured into the vertical retaining slot 170 by means of bolts 174 and sliding plate 120 as described above. A threaded positioning element 176 is inserted into a threaded hole 186 in the sliding assembly 182 as shown and retained in a desired position by nut 178. Connecting element 180 secures a pivotable locating element 182 to the threaded positioning element 176 by means of bolt 184 and a threaded hole into the connecting element 180 as shown. 
     In operation, pivotable locating element 182 can be secured at a desired location for positioning a workpiece as shown in FIG. 1. As is apparent, locating element 182 can be positioned in all X, Y and Z axes individually from each other. Further, the locating element 182 is pivotable on the tab of the connecting element 180 so as to push against the workpiece at an efficient or desired angle. 
     Now turning to FIG. 8, flush mounted B or C datum locator alignment device 234 is shown which operates in much the same fashion as the alignment device 28 of FIG. 7. This alignment device is used for workpieces which need to be positioned near platform 12. Generally, stanchions 32 are not required for this device. Headers 202 are instead inserted directly into the threaded holes 16 by means of the threaded end portion 214 and the screw drive slot as shown. Once the headers 202 are threaded into hole 16 a bridging member 200 is positioned over the headers 202, such that the headers are inserted into holes 206. The headers 202 are secured in the holes 206 by means of set screws 208 positioned in grooves 212 formed by flanges 210. The bridging member 200 has a dovetailed slot 204 for positioning sliding assembly 216. Sliding assembly 216 is secured by means of bolt 220 and slidign plate 120 as described above. In this alignment device 234, there generally is not a need for using set screws to further secure sliding assembly 216 as described in FIg. 5. Sliding assembly 172, from FIG. 7, is positioned in the dovetail slot 222 of sliding assembly 216 as described in FIG. 7. Pivotable locating head 232 is used in much the same way as the pivotable head 182 of FIG. 7. 
     The universality of the disclosed alignment devices enables the support and positioning of virtually any size and shape workpiece. FIG. 1 shows only one arrangement of the alignment devices. Virtually every horizontal point above the platform 12 within the vertical range of the alignment devices can be accessed. Moreover, the alignment devices as disclosed are not limited for use with a device for inspection of a workpiece. Further uses include structural testing, assembly and machining processes of workpieces. In addition, the invention employs a modular, building block approach where many of the elements are interchangeable and are commonly used in many different species of the alignment devices. Various modifications of the disclosed alignment devices can be made without departing from the spirit and scope of the invention as set forth in the following claims.